Golf Ball With Thin Biaxial Film Outer Layer

ABSTRACT

Systems and methods for manufacturing a golf ball are disclosed. In some embodiments, a thermoplastic film may be manipulated causing the molecules in the film to become biaxially oriented. In some embodiments, a robotic arm may manipulate the thermoplastic film. In some embodiments, a robotic arm may manipulate the golf ball core in order to dispose the thermoplastic film around the golf ball core. In some embodiments, a robotic arm may position the golf ball components in a mold. In some embodiments, a robotic arm may remove the golf ball components from a mold. In some embodiments, the mold may be associated with a conveyer belt.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/578,347, entitled “Golf Ball With Thin Biaxial Film Outer Layer”, and filed on Dec. 21, 2011, which application is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The embodiments herein relate to system and methods for manufacturing a golf ball. More specifically, the systems and methods relate to manipulating and disposing a thermoplastic film around a golf ball core. The systems and methods also relate to manipulating the golf ball core with a robotic arm during the manufacturing process.

2. Description of Related Art

Golf ball manufacturers are continuously researching how to enable golf balls to travel further distances with the same amount of strike force. For example, manufacturing a golf ball with a thinner outer cover allows the inner core, usually made of rubber, to be larger. This enables the golf ball to fly with a greater velocity and, consequently, travel a greater distance.

Previous golf balls having thin outer layers use an injection molding process to form the outer layer. However, injection molding an outer layer that is less than 0.90 mm thick becomes difficult due to the constraints of pressurizing the molten plastic. Additionally, problems arise when attempting to control the flow of the molten plastic while attempting to evenly distribute the molten plastic around the golf ball core during the injection molding process. These problems are present regardless of whether the golf ball core is made of elastomer, resin, or a combination of both.

In order to avoid the problems of injection molding, the current embodiments described herein are directed toward using a thermoplastic film. More specifically, a biaxially oriented thermoplastic film may allow for a thin outer layer that exhibits greater strength than injection molded layers.

SUMMARY OF THE INVENTION

Systems and methods for manufacturing a golf ball are disclosed. In some embodiments, a thermoplastic film may be manipulated causing the molecules in the film to become biaxially oriented. In some embodiments, a robotic arm may manipulate the thermoplastic film. In some embodiments, a robotic arm may manipulate the golf ball core in order to dispose the thermoplastic film around the golf ball core. In some embodiments, a robotic arm may position the golf ball components in a mold. In some embodiments, a robotic arm may remove the golf ball components from a mold. In some embodiments, the mold may be associated with a conveyer belt.

In one aspect, a method of preparing thermoplastic film is disclosed. In some embodiments, the method may include providing a sheet of thermoplastic film. In some embodiments, the method may further include providing a heat source. In some embodiments, the method may further include applying the heat source to the thermoplastic film. In some embodiments, the method may further include stretching the thermoplastic film in a first direction. In some embodiments, the method may further include stretching the thermoplastic film in a second direction, wherein the second direction is substantially perpendicular to the first direction.

In another aspect, a method for manufacturing a golf ball is disclosed. In some embodiments, the method may include disposing a biaxial thermoplastic film on an outer surface of a golf ball core. In some embodiments, the method may further include providing a robotic arm. In some embodiments, the method may further include gripping the golf ball core having the biaxial thermoplastic film disposed around the outer surface of the golf ball core with the robotic arm. In some embodiments, the method may further include providing a first mold half having a first inner surface and a first outer surface. In some embodiments, the method may further include providing a second mold half having a second inner surface and a second outer surface, wherein the second inner surface is facing the first inner surface. In some embodiments, the method may further include positioning the golf ball core having the biaxial film disposed on the outer surface of the golf ball core between the first inner surface and second inner surface using the robotic arm.

Other systems, methods, features and advantages of the current embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The current embodiments can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the current embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 is a schematic view of one embodiment of a robotic arm;

FIG. 2 is a schematic view of the robotic arm shown in FIG. 1 preparing to grip an object;

FIG. 3 is a schematic view of the robotic arm shown in FIGS. 1-2 gripping an object;

FIG. 4 is a schematic view of an embodiment for unrolling a film for golf balls;

FIG. 5 is a schematic view of an embodiment for applying heat to a film;

FIG. 6 is a schematic view of an embodiment for stretching a film for golf balls in a first direction;

FIG. 7 is a schematic view of an embodiment for stretching a film for golf balls in a second direction;

FIG. 8 is an embodiment of a method of manufacturing a film for golf balls;

FIG. 9 is a schematic view of an embodiment for positioning a golf ball core with a robotic arm;

FIG. 10 is a schematic view of an embodiment for folding a film around a golf ball core using a robotic arm;

FIG. 11 is another schematic view of an embodiment for folding a film around a golf ball core using a robotic arm;

FIG. 12 is an embodiment of a method for manufacture a golf ball using a robotic arm;

FIG. 13 is a schematic view of an embodiment for manufacturing a golf ball using at least one robotic arm and two sheets of film;

FIG. 14 is an embodiment of a method for manufacturing a golf ball using at least one robotic arm and two sets of film;

FIG. 15 is a schematic view of an embodiment for positioning golf ball components in a mold using a robotic arm;

FIG. 16 is a schematic view of an embodiment for golf ball components in a mold;

FIG. 17 is a schematic view of an embodiment for removing a golf ball from a mold using a robotic arm;

FIG. 18 is a schematic view of an embodiment of a conveyer belt assembly for manufacturing a golf ball; and

FIG. 19 is a schematic view of another embodiment of a conveyer belt assembly for manufacturing a golf ball.

DETAILED DESCRIPTION

Embodiments provide systems and methods for applying a thermoplastic film of one or more layers to the core of a golf ball. More specifically, a thermoplastic film that is biaxially oriented provides for a stronger and thinner outer layer.

For the purposes of this disclosure, the term “golf ball” refers to any generally spherically shaped ball which may be used in playing the game of golf.

For the purposes of this disclosure, the term “core” normally refers to those portions of a golf ball which are closer to or proximate the center of the golf ball. The core may have multiple layers, where the centermost portion of the golf ball is the “core” or “inner core” and any surrounding core layers are “outer core” layers.

For the purposes of this disclosure, the term “mantle” generally refers to an optional layer or layers of a golf ball which may be positioned between the core layer or layers and the outermost cover, and which may be proximate or adjacent to the cover.

For the purposes of this disclosure, the term “cover” generally refers to the outermost layer of a golf ball, which often has a pattern of dimples (dimple pattern) on the outer surface thereof.

For the purposes of this disclosure, the term “dimple” refers to an indentation in or a protrusion from the outer surface of a golf ball cover that is used to control the flight of the golf ball. Dimples may be hemispherical (i.e., half of a sphere) or semi-hemispherical (i.e., a part or portion of a hemisphere) in shape, including various combinations of hemispherical and semi-hemispherical dimples, but may also be elliptical-shaped, square-shaped, polygonal-shaped, such as hexagonal-shaped, etc. Dimples which are more semi-hemispherical in shape may be referred to as being “shallower” dimples, while dimples which are more hemispherical in shape may be referred to as being “deeper” dimples.

For the purposes of this disclosure, the term “dimple pattern” refers to an arrangement of a plurality of dimples on the outer surface of the cover of a golf ball. The dimple pattern may comprise dimples having the same shape, different shapes, different arrangements of dimples within the pattern (both as to shape and/or size), repeating subpatterns (i.e. a smaller pattern of dimples arranged within the dimple pattern), such as spherical triangular, etc. In some embodiments, the total number of dimples in the dimple pattern may be in the range of from about 250 to about 500, for example, from about 300 to about 400. The total number of dimples in the dimple pattern is often an even number of dimples, but may also be an odd number of dimples.

For the purposes of this disclosure, the term “thermoplastic” refers to the conventional meaning of the term thermoplastic, i.e., a composition, compound, material, medium, substance, etc., which exhibits the property of a material, such as a high polymer, that softens when exposed to heat and generally returns to its original condition when cooled to room temperature (e.g., at from about 20° C. to about 25° C.).

For the purposes of this disclosure, the term “thermoset” refers to the conventional meaning of the term thermoset, i.e., a composition, compound, material, medium, substance, etc., that is cross-linked such that it does not have a melting temperature, and cannot be dissolved in a solvent, but which may be swelled by a solvent.

For the purposes of this disclosure, the term “polymer” refers to a molecule having more than 30 monomer units, and which may be formed or result from the polymerization of one or more monomers or oligomers.

For the purposes of this disclosure, the term “oligomer” refers to a molecule having 2 to 30 monomer units.

For the purposes of this disclosure, the term “monomer” refers to a molecule having one or more functional groups and which is capable of forming an oligomer and/or polymer.

For the purposes of this disclosure, the term “ionomer” refers to a monomer having at least one carboxylic acid group, and which may be at least partially or completely neutralized by one or more bases (including mixtures of bases) to provide carboxylic acid salt monomers (or mixtures of carboxylic acid salt monomers). For example, the ionomer may comprise a mixture of carboxylic acid sodium and zinc salts monomers, such as the mixed ionomer used in making the ionomer resin sold under DuPont's trademark SURLYN® for cut-resistant golf ball covers.

For the purposes of this disclosure, the term “ionomer resin” refers to an oligomer or polymer which may comprise, or be formed, from one or more ionomer units or ionomers, and which may be a copolymer of one or more ionomers (such as methacrylic acid which is at least partially or completely neutralized) and one or more monomers or oligomers which is not an ionomer, such as, for example, ethylene.

For the purposes of this disclosure, the term “elastomer” refers to oligomers or polymers having the property of elasticity, and may be used interchangeably with the term “rubber” herein.

For the purposes of this disclosure, the term “polyol” refers to an organic molecule having two or more hydroxy functional groups.

For the purposes of this disclosure, the term “polyurethane” refers to a polymer which is joined by urethane (carbamate) links, and which may be prepared, for example, from polyols (or compounds forming polyols such as by ring-opening mechanisms, e.g., epoxides) and polyisocyanates. Polyurethanes useful herein may be thermoplastic or thermosetting, but are thermoplastic when used in the cover. The soft segment of a thermoplastic polyurethane may also be partially cross-linked, for example, with a hyper branched or dendritic polyol, to provide improved scuff resistance, increased hardness, etc.

For the purposes of this disclosure, the term “Shore D” refers to a measure of the hardness of a material by a durometer, and especially the material's resistance to indentation. Shore D hardness may be measured with a durometer directly on the curved surface of the core, layer, cover, etc., according to ASTM method D2240. In other embodiments, the hardness may be measured using standard plaques.

In some embodiments, the golf ball made by the disclosed method may include a golf ball having a core and a cover layer. In some embodiments, the golf ball may have an inner core and an outer core. In some embodiments, the golf ball may have multiple cover layers. In some embodiments, the golf ball may also include a mantle layer, also known as a “three-piece” golf ball. In some embodiments, a thermoplastic film may be used as a mantle layer. In some embodiments, a thermoplastic film may form the cover of the golf ball. In some embodiments, an outer coating may be applied over the cover of the golf ball. In some embodiments, ethylene vinyl acetate may be used to adhere one layer of the golf ball to another layer.

In some embodiments, certain layers of the golf ball may contain one or more of the following types of material: polyol, elastomer, polyurethane, ionomer, ionomer resin, monomer, oligomer, and/or polymer. In some embodiments, the golf ball core may comprise a single solid core, often made of cross-linked rubber such as polybutadiene which may be chemically cross-linked with zinc diacrylate and/or similar cross-linking agents. In some embodiments, the core may be formed from Dupont® HPF resins. In some embodiments, the core may be formed from other components known to those skilled in the art.

In some embodiments, the golf ball core may be covered with SURLYN® (the trademark for an ionomer resin produced by DuPont) to provide, a tough, cut-proof blended cover. In some embodiments, the cover layer(s) may be made from a highly neutralized acid polymer.

The thermoplastic film may be any type of thermoplastic material known in the art. For example, in some embodiments, the thermoplastic material may be a polypropylene. In some embodiments, the thermoplastic material may be a thermoplastic polyurethane material, such as Estane 58219, which is commercially available by the Lubrizol Corporation. In some embodiments, the thermoplastic film may be manufactured by Nike IHM, Inc. In some embodiments, the thermoplastic film may be manufactured by BASF Corporation. In some embodiments, ethylene vinyl acetate may be used to adhere the thermoplastic resin to the golf ball core.

In some embodiments, the thermoplastic film may be a multi-layer film. In some embodiments, a multi-layer film may be made by a casting process that involves extruding a plurality of individual film layers together through a die and onto a roller. In some embodiments, the thermoplastic film may be preheated before extrusion. In some embodiments, the thermoplastic film may be heated during extrusion. In some embodiments, the thermoplastic film may be chilled to set the individual layers as a single multi-layer film after extrusion. In some embodiments, the extruded film may be pulled to in biaxial directions after extrusion. In some embodiments, the individual layers may be about 0.1 millimeter thick and the multi-layer film may include from 2 to 10 layers such that the multi-layer film has a thickness of about 0.2 millimeters to about 1 millimeter.

In some embodiments, the thermoplastic film may contain one or more materials having different properties. These materials may, for example, enhance the hardness of the material. The film may also have a base extruded or cast layer with additional layers sprayed on. These additional layers may also have one or more materials having different properties.

In some embodiments, provisions may be made to strengthen thermoplastic film used in manufacturing golf balls. For example, in some embodiments a combination of heating and stretching processes may be applied to the film. In some embodiments, the stretching processes may be performed using robotic arms in order to more accurately position the golf ball components during the manufacturing process. In other embodiments, any machinery may be used to perform the heating and/or stretching processes.

In some embodiments, a robotic arm may be utilized during the manufacture of a golf ball. For the purposes of this disclosure, the term “robotic arm” refers to any electrical/mechanical device capable of manipulating and/or positioning sheets of film and/or golf ball cores. In some embodiments, robotic arms may be controlled by electrical signals carried by electrical wires connected to the robotic arm. In other embodiments, robotic arms may be controlled mechanically, such as by hydraulics. In still further embodiments, other systems known to those skilled in the art may be used to manipulate and control robotic arms.

In some embodiments, robotic arms may be electronically connected to a microprocessor, RAM, ROM, and software all serving to monitor and supervise various parameters of the robotic arm 100. Electronic signals to and from the robotic arm may be processed by a central processing unit (CPU) in accordance with software stored in an electronic memory, such as ROM or RAM. In some embodiments, robotic arms may be pre-programmed so that the movements of the robotic arms are automated. In other embodiments, movements of the robotic arm may be controlled manually and/or remotely.

In some embodiments, a robotic arm as shown in FIGS. 1-3 may be used in conjunction with manufacturing a golf ball. FIG. 1 shows the various components of one embodiment of a robotic arm 100. In some embodiments, a robotic arm 100 may include a first gripping member 102. First gripping member 102 may include a first gripping end 107 and a first attachment end 109. The first gripping end 107 may include a first contact surface 103 for contacting an object (not shown) for manipulation. Similarly, robotic arm 100 may include a second gripping member 104. Second gripping member 104 may include a second gripping end 106 and a second attachment end 108. The second gripping end 106 may include a second contact surface 105.

The first attachment end 109 of the first gripping member 102 may be attached to the second attachment end 108 of the second gripping member 104 at an attachment portion 110 of the robotic arm 100. A securing member 111 may attach the first gripping member 102 to the second gripping member 104 at the attachment portion 110. In some embodiments, securing member 111 may include one or more screw(s), bolt(s), fastener(s), or any other mechanism known to those skilled in the art for securing two members together. The attachment portion 110 of robotic arm 100 may be attached to arm extension 112. The arm extension 112 may move in any direction in order to position the robotic arm 100 in the desired location. For example, arm extension 112 may extend outwardly, retract, or rotate in order to maneuver the robotic arm 100 into a desired position.

FIG. 2 shows the robotic arm 100 shown in FIG. 1 preparing to grip an object 115. As the extension arm 112 moves the robotic arm 100 near the object 115, electrical or mechanical signals may cause the first gripping member 102 to pivot about the securing member 111 in an opening direction 114. This causes the first gripping end 107 to move in a direction 113 that is away from the second gripping end 106. Once the desired object 115 is exposed to the first contact surface 103 and second contact surface 105, the extension arm 112 may advance the robotic arm 100 towards the object 115.

In some embodiments, the object 115 may be a golf ball core. In other embodiments, the object 115 may be a sheet of thermoplastic film. In still further embodiments, the object 115 may be any item.

FIG. 3 shows the robotic arm 100 shown in FIGS. 1-2 gripping a desired object 115. As the object 115 is positioned between the first contact surface 103 and the second contact surface 105, electrical or mechanical signals cause the first gripping member 102 to rotate about the securing member 111 in a closing direction 116. This causes the first contact surface 103 to move in a direction 117 towards the second contact surface 105, until the first contact surface 103 and second contact surface 105 are brought into contact with the object 115.

The mechanical and/or electrical structure of the robotic arm 100 may vary. In some embodiments, both the first gripping member 102 and the second gripping member 104 may pivot about the securing member 111. Although FIGS. 1-3 illustrate a robotic arm 100 having two gripping members, other embodiments may include more than two gripping members. In some embodiments, components of the robotic arm 100 may be made from plastic, metal, an alloy, and/or other composite (or non-composite) material know to those skilled in the art.

In some embodiments, the shape of the first contact surface 103 and second contact surface 105 may vary. In some embodiments, the first contact surface 103 and/or second contact surface 105 may generally have a circular, square, rectangular, triangular or any other geometric or non-geometric shape. In some embodiments, one or more contact surfaces may have the same shape. In other embodiments, one or more contact surfaces may have a different shape.

In some embodiments, robotic arms may improve the process for manufacturing golf balls. The speed at which automated robotic arms can maneuver various golf ball components may decrease the amount of time it takes to manufacture each golf ball. In addition, robotic arms can manipulate golf ball components with improved accuracy, which increases the quality of each golf ball.

FIGS. 4-7 illustrate one embodiment 400 of methods and systems for manufacturing a biaxial film for golf balls using one or more robotic arm(s). In some embodiments, the robotic arm 100 discussed in FIGS. 1-3 may be used in the embodiment 400 shown in FIGS. 4-7. In some embodiments, robotic arms may be used to unroll a thermoplastic sheet. FIG. 4 shows a roll of thermoplastic film 405 with an end edge 427 extended from the roll. In some embodiments, the end edge 427 may be extended in an outwardly direction 425 by a first robotic arm 435 and/or a second robotic arm 430 as the roll of film 405 remains stationary. In some embodiments, some other clamping or securing device known to those skilled in the art may be used instead of, or in conjunction with, the first robotic arm 435 and/or second robotic arm 430 shown in FIG. 4. One skilled in the art would recognize other methods of extending the end edge 427 of the roll of thermoplastic material 405. For example, in other embodiments, the end edge 427 may be held stationary by first robotic arm 435 and/or second robotic arm 430, while the roll of film 405 is moved away from the end edge 427.

In some embodiments, a heat source may be applied to the thermoplastic film in order to prepare the film for further processing. Referring to FIG. 5, a heat source 420 may be applied to the exposed portion 440 of the thermoplastic film. In some embodiments, the exposed portion 440 of the thermoplastic film is heated to a temperature that is below the melting point of the film. In some embodiments, the exposed portion 440 may be heated to a temperature that is above the glass transition temperature of the film. Any heat source 420 may be applied in order to raise the temperature of the thermoplastic film. Raising the temperature of the film allows the polymer molecules to be more easily oriented in a desired axial direction.

In some embodiments, the film may be preheated before stretching, as described with reference to FIGS. 6 and/or 7 below. For example, in some embodiments, before stretching the film, the film may be preheated to a temperature that is about 86 degrees Fahrenheit (30 degrees Celsius) to about 122 degrees Fahrenheit (50 degrees Celsius) below the melting point of the film for a period of about 15 seconds to about 2 minutes. In some embodiments, before stretching the film, the film may be preheated to a temperature that is about 35 degrees Celsius to about 45 degrees Celsius below the melting point of the film for a period of about 30 seconds to about 1.5 minutes. For example, in embodiments in which the film is made of Estane 58219(melting temperature of 284 degrees Fahrenheit (140 degrees Celsius)), the film may be preheated to a temperature of about 212 degrees Fahrenheit (100 degrees Celsius) for about 1 minute.

In some embodiments, the film may be heated while being stretched. This heating may occur with or without the preheating discussed above. The film may be heated to a temperature that is about 41 degrees Fahrenheit (5 degrees Celsius) to about 77 degrees Fahrenheit (25 degrees Celsius) below the melting point of the film for a period of about 5 seconds to about 1.5 minutes. In some embodiments, before stretching the film, the film may be preheated to a temperature that is about 50 degrees Fahrenheit (10 degrees Celsius) to about 113 degrees Fahrenheit (45 degrees Celsius) below the melting point of the film for a period of about 15 seconds to about 1 minute. For example, in embodiments in which the film is made of Estane 58219(melting temperature of 284 degrees Fahrenheit (140 degrees Celsius)), the film may be heated to a temperature of about 257 degrees Fahrenheit (125 degrees Celsius) for about 30 seconds.

In embodiments in which the melting temperature of the film is higher than that of Estane 58219, the exposed portion 440 of the thermoplastic film may be heated to between about 400 degrees Fahrenheit (204 degrees Celsius) and about 500 degrees Fahrenheit (260 degrees Celsius). In other embodiments, the exposed portion 440 of the thermoplastic film may be heated to below 400 degrees Fahrenheit (204 degrees Celsius). In still further embodiments, the exposed portion 440 of the thermoplastic film may be heated to above 500 degrees Fahrenheit (260 degrees Celsius).

In some embodiments, as illustrated in FIG. 6, force may be exerted on the extended portion 440 of thermoplastic film in order to align the molecules along a first axial direction 450. Referring to FIG. 6, a first robotic arm 435 and/or a second robotic arm 430 may pull on the end edge 427 of the roll of thermoplastic film in a first direction 426 away from the roll 405 in order to exert force on the extended portion 440. Exerting force in the first direction 426 may align some of the polymer molecules along a first axial direction 450. In some embodiments, first robotic arm 435 and/or second robotic arm 430 may hold the end edge 427 of the thermoplastic film steady while the thermoplastic roll 405 is moved away from one end edge 427. In some embodiments, the extended portion 440 may be cut or separated from the roll 405 of thermoplastic film. In such embodiments, more than two robotic arms may be utilized in order to align the polymer molecules in the first axial direction 450.

The amount of force exerted on the extended portion 440 may vary. In some embodiments, first robotic arm 435 and/or second robotic arm 430 may exert up to 1,110 Newtons on the extended portion 440. In some embodiments, more than 1,110 Newtons may be exerted on the extended portion 440. For example, in some embodiments 1,200 Newtons may be exerted on the extended portion. In other embodiments, less than 1,110 Newtons may be exerted on the extended portion. For example, in some embodiments 1,000 Newtons may be exerted on the extended portion 440. In some embodiments, the force exerted on the extended portion is adequate to align some of the polymer molecules along a first axial direction 450.

Although first robotic arm 435 and second robotic arm 430 are shown in FIG. 6 exerting force on the extended portion 440, one skilled in the art would recognize other methods of securing or gripping thermoplastic film. In some embodiments, a clamping or securing device may be used instead of first robotic arm 435 and second robotic arm 430.

In some embodiments, as illustrated in FIG. 7, force may be exerted on the extended portion 440 of thermoplastic film in order to align some of the polymer molecules along a second axial direction 460. Referring to FIG. 7, a first robotic arm 435 may grip a first side edge 455 and pull in a first direction 459. A second robotic arm 430 may grip a second side edge 457 and pull in a second direction 458. In some embodiments, a third robotic arm 432 may grip the second side edge 457 and pull in the second direction 458. In some embodiments, a fourth robotic arm 437 may grip the first side edge 455 and pull in the first direction 459. Although FIG. 7 shows four robotic arms, more or less robotic arms may be utilized.

The amount of force exerted on the extended portion 440 in FIG. 7 may vary. In some embodiments, the robotic arms may exert up to 1,110 Newtons on the extended portion 440. In some embodiments, more than 1,110 Newtons may be exerted on the extended portion 440. For example, in some embodiments 1,200 Newtons may be exerted on the extended portion. In other embodiments, less than 1,110 Newtons may be exerted on the extended portion. For example, in some embodiments 1,000 Newtons may be exerted on the extended portion 440. In some embodiments, the force exerted on the extended portion 440 is adequate to align some of the polymer molecules along a second axial direction 460.

Although robotic arms are illustrated in FIG. 7, one skilled in the art would recognize other methods of securing or gripping thermoplastic film. In some embodiments, a clamping or securing device may be used instead of robotic arms. In some embodiments, force may be applied after being subjected to a heating process. However, in other embodiments, the heating process may be applied after the stretching processes shown in FIGS. 6 and/or 7.

In some embodiments, second axial direction 460 in FIG. 7 may be substantially perpendicular to first axial direction 450 in FIG. 6. Thermoplastic film having some of the polymer molecules oriented substantially 90° from other polymer molecules may increase the strength of the thin layers of thermoplastic film.

FIGS. 6 and 7 show an embodiment in which the extended portion 440 is sequentially stretched in two different axial directions. In some embodiments, the extended portion 440 may be simultaneously stretched in two different axial directions. For example, a linear motor simultaneous stretching technology (LISIM) may be used to simultaneously stretch the extended portion 440 in two different axial directions. Simultaneously stretching the extended portion 440 may result in a thinner film than sequentially stretching the extended portion 440. For example, in some embodiments, simultaneously stretching the extended portion 440 may result in a film having a stretch ratio (based on the thickness of the film before and after stretching) of between about 8:1 and about 10:1. Meanwhile, sequentially stretching the extended portion 440 may result in a film having a stretch ratio of about 4:1 to about 5:1. In some embodiments, the amount of force exerted on the extended portion 440 may be determined by the desired stretch ratio (based on the thickness of the film before and after stretching). For example, in some embodiments, the extended portion 440 may be stretched until the thickness of the extended portion 440 has been reduced such that the stretch ratio is 9:1. In some embodiments, the extended portion 440 may be heated after each stretching to set the extended portion 440.

FIG. 8 is one embodiment of a method 800 of manufacturing a thermoplastic film for golf balls. It will be understood that in some embodiments one or more of the following steps may be optional. In step 810, a heat source may be applied to an extended portion of a roll of thermoplastic film. In some embodiments, a heat source 420 may be applied as described in FIG. 5. In step 820, the thermoplastic film may be stretched in a first direction. In some embodiments, the film may be stretched as described in FIG. 6. In step 830, the thermoplastic film may be stretched in a second direction. In some embodiments, the second direction may be substantially perpendicular to the first direction. In some embodiments, the thermoplastic film may be stretched as described in FIG. 7.

Although a roll 405 of thermoplastic film is depicted in FIGS. 4-8, the current embodiments are not so limited. For example, FIGS. 4-8 may be directed to a sheet of thermoplastic film instead of a roll 405 of thermoplastic film. The sheet of thermoplastic film may be preformed into various shapes in order to optimize the manufacturing process. In some embodiments, the sheet of thermoplastic film may be rectangular, circular, oval, or any other geometrical or non-geometrical shape.

Although FIGS. 4-8 include robotic arms in manufacturing biaxial film, other embodiments may not include robotic arms. For example, the thermoplastic film may be fed into machinery that performs the processes described in FIGS. 4-8.

FIGS. 9-11 illustrate methods and systems 900 for disposing a thermoplastic film on a golf ball core using one or more robotic arms. While a golf ball core is shown in FIGS. 9-11, it is understood that the method may be used to apply a thermoplastic film to any layer of a golf ball. For example, in some embodiments, the method may be used to apply the thermoplastic film to a mantle and/or a cover layer of a golf ball. FIG. 9 is a schematic view of one embodiment of extending a thermoplastic sheet from a roll using a robotic arm. FIG. 9 shows a roll 905 of thermoplastic film with the end edge 910 extended from the roll 905. In some embodiments, the end edge 910 may be extended in an outwardly direction 915 by a first robotic arm 940 and/or a second robotic arm 945 as the roll of film 905 remains stationary. In other embodiments, the end edge 910 may be held stationary by first robotic arm 940 and/or second robotic arm 945, while the roll of film 905 is moved away from the end edge 910. In some embodiments, some other clamping or securing device known to those skilled in the art may be used instead of, or in conjunction with, the first robotic arm 940 and/or second robotic arm 945. One skilled in the art would recognize other methods of extending the end edge 910 of the roll 905 of thermoplastic film.

Once the extended portion 950 of the film has been extended, a third robotic arm 930 may position a golf ball core 920 in contact with a surface 955 of the extended portion 950. In some embodiments, the extended portion 950 of the roll 905 of thermoplastic film may have undergone the processes described in FIGS. 4-8. In other embodiments, the entire roll 905 may have undergone the processes described in FIGS. 4-8.

In some embodiments, provisions may be made for folding thermoplastic film into an L-shape around a golf ball core using robotic arms. In some embodiments, robotic arms may fold the thermoplastic film in addition to positioning the golf ball core. As can be seen in FIG. 10, first robotic arm 940 and/or second robotic arm 945 may pull upwards 970 on the end edge 910 of the extended portion 950. A crease 960 may form in the extended portion 950 of the thermoplastic film, bending the extended portion 950 into an L-shape. In some embodiments, the robotic arm 940 and/or second robotic arm 945 may hold the end edge 910 of the thermoplastic film steady while the entire roll 905 is maneuvered in order to create a crease 960, generally bending the extended portion 950 into an L-shape. In some embodiments, third robotic arm 930 may continue to hold the golf ball core 920 on the surface 955 of the extended portion 950, so that the golf ball core 920 is in contact with the crease 960. In some embodiments, a clamping or securing device may be used instead of the first robotic arm 940, second robotic arm 945, and/or third robotic arm 930.

In some embodiments, provisions may be made for folding thermoplastic film into a U-shape around a golf ball core using robotic arms. In some embodiments, robotic arms may fold the thermoplastic film in addition to positioning the golf ball core. As can be seen in FIG. 11, a first robotic arm 940 and/or second robotic arm 945 may continue to fold the extended portion 950 of the roll 905 of thermoplastic film shown in FIG. 10. In some embodiments, first robotic arm 940 and/or second robotic arm 945 may pull the extended portion 950 in direction 975. This may cause the extended portion 950 to form a U-shape around the golf ball core 920. In some embodiments, the first robotic arm 940 and/or second robotic arm 945 may hold the end edge 910 of the thermoplastic film steady while the entire roll 905 is maneuvered in order to fold the extended portion 950 into a U-shape. In some embodiments, third robotic arm 930 may continue to hold the golf ball core 920 on the surface 955 of the extended portion 950, so that the golf ball core 920 is in contact with the crease 960. In some embodiments, a clamping or securing device may be used instead of the first robotic arm 940, second robotic arm 945, and/or third robotic arm 930.

FIG. 12 is an embodiment of a method 1200 for manufacturing a golf ball using a robotic arm. It will be understood that in some embodiments one or more of the following steps may be optional. In step 1210, a robotic arm may hold a golf ball core in contact with a surface of a thermoplastic film. In some embodiments, this step may be performed in accordance with the description of FIG. 9. In step 1220, the thermoplastic film may be bent into an L-shape around the golf ball core. The robotic arm may hold the golf ball core in contact with the crease of the thermoplastic film as the film is folded into an L-shape. In some embodiments, this step may be performed in accordance with the description of FIG. 10. In step 1230, the thermoplastic film may be folded into a U-shape. The robotic arm may hold the golf ball core in contact with the crease of the thermoplastic film as the film is folded into a U-shape. In some embodiments, this step may be performed in accordance with the description of FIG. 11.

FIG. 13 is a schematic view of an alternative embodiment of methods and systems 1300 for manufacturing a golf ball using at least one robotic arm and two sets of thermoplastic films. In some embodiments, robotic arms may fold the thermoplastic film in addition to positioning the golf ball core. Referring to FIG. 13, a first roll 1305 of thermoplastic film may be positioned near a golf ball core 1330. The end edge 1307 of the first roll 1305 of thermoplastic film may be extended by a first robotic arm 1340, exposing a first extended portion 1360. In other embodiments, the first robotic arm 1340 may hold the end edge 1307 of the first extended portion 1360 steady while the entire first roll 1305 is maneuvered. The first extended portion 1360 may include a first surface 1364 facing a first half 1332 of the golf ball core 1330, and a second surface 1362 facing away from the golf ball core 1330.

Similarly, a second roll 1310 of thermoplastic film may be positioned near the golf ball core 1330. The end edge 1315 of the second roll 1310 of thermoplastic film may be extended by a second robotic arm 1350, exposing a second extended portion 1370. In other embodiments, the second robotic arm 1350 may hold the end edge 1315 of the second extended portion 1370 steady while the entire second roll 1310 is maneuvered. The second extended portion 1370 may include a first surface 1372 facing a second half 1334 of the golf ball core 1330, and a second surface 1374 facing away from the golf ball core 1330.

In some embodiments, a third robotic arm 1320 may position the golf ball core 1330 so that the second half 1334 of the golf ball core 1330 contacts the first surface 1372 of the second extended portion 1370 of the second roll 1310 of thermoplastic film. In addition, the first surface 1364 of the first extended portion 1360 of the first roll 1305 of thermoplastic film may be brought into contact with a first half 1332 of the golf ball core 1330. In other embodiments, a clamping or securing device may be used instead of the first robotic arm 1340, second robotic arm 1350, and/or third robotic arm 1320.

Third robotic arm 1320 may continue to grip golf ball core 1330 while both sheets of thermoplastic film are positioned onto the outer surface of the golf ball core 1330. In some embodiments, the third robotic arm 1320 may continue to grip the golf ball core 1330 in place while the first surface 1364 of the first extended portion 1360 is positioned onto a first half 1332 of the golf ball core 1330. In some embodiments, the third robotic arm 1320 may continue to grip the golf ball core 1330 while the first surface 1372 of the second extended portion 1370 is positioned onto a second half 1334 of the golf ball core 1330.

In some embodiments, the properties of the thermoplastic film shown in FIG. 13 may vary. In some embodiments, the first extended portion 1360 and/or second extended portion 1370 may have undergone the processes described in FIGS. 1-4. In some embodiments, the first extended portion 1360 and/or second extended portion 1370 may be biaxial. In other embodiments, the entire first roll 1305 and/or second roll 1310 may have undergone the processes described in FIGS. 1-4. In still further embodiments, forces exerted on the first extended portion 1360 and/or second extended portion 1370 during later molding processes may cause the first extended portion 1360 and/or second extended portion 1370 to become substantially biaxial.

In some embodiments, the robotic arms may position the various golf ball components shown in FIG. 13 in a mold for further processing.

In some embodiments, first robotic arm 1340 may continue to hold the end edge 1307 of the first extended portion 1360 until the first extended portion 1360 is placed in a mold. Similarly, second robotic arm 1350 may continue to hold the end edge 1315 of the second extended portion 1370 until the second extended portion 1370 is placed in a mold. In some embodiments, third robotic arm 1320 may move the golf ball core 1330 to the location of a mold once the first surface 1364 of the first extended portion 1360 is placed on the first half 1332 of the core 1330 and the first surface 1372 of the second extended portion 1370 is placed on the second half 1334 of the core 1330. In other embodiments, the first extended portion 1360 and the second extended portion 1370 and golf ball core 1330 may already be located near a mold.

FIG. 14 is an embodiment of a method 1400 for manufacturing a golf ball using at least one robotic arm and two sets of thermoplastic films. It will be understood that in some embodiments one or more of the following steps may be optional. In some embodiments, the steps shown in FIG. 14 may be carried out in accordance with the description of FIG. 13. In step 1410, a robotic arm may grip a golf ball core during the manufacturing process. In step 1420, a first sheet of thermoplastic film may be placed near a first half of a golf ball core. In step 1430, a second sheet of thermoplastic film may be placed near a second half of the golf ball core. In step 1440, the second sheet of thermoplastic film may be brought into contact with the golf ball core. In step 1450, the first sheet of thermoplastic film may be brought into contact with the golf ball core.

FIGS. 15-17 show one embodiment of methods and systems for using one or more robotic arms during the molding process of golf ball manufacturing. In some embodiments, the processes described in FIGS. 15-17 may be performed on the golf ball components described in FIGS. 4-14.

FIG. 15 is a schematic view of systems and methods of at least one robotic arm positioning golf ball components into a mold for further processing. In this embodiment, a robotic arm 1510 may assist in positioning a golf ball core 1510 enveloped in thermoplastic film 1515 during the molding process. As can be seen in FIG. 15, the robotic arm 1505 may position a golf ball core 1510 covered with a thermoplastic film 1515 between a first mold half 1520 and a second mold half 1530. The speed of the robotic arm 1505 may help to decrease the overall manufacturing time of each golf ball, while the positioning accuracy of the robotic arm 1505 may help to increase the overall quality of each golf ball.

In some embodiments, the mold design used for manufacturing golf balls may vary. For example, in some embodiments, the mold may have projections on an inner surface in order to form dimples on the golf ball. Referring to FIG. 15, in one embodiment, the first mold half 1520 may have one or more protuberances 1525 located on a first curved inner surface 1522. Likewise, second mold half 1530 may have one or more protuberances 1535 on a second curved inner surface 1532. The protuberances 1525 on the first curved inner surface 1522 of the first mold half 1520, as well as the protuberances 1535 on the second curved inner surface 1532 of the second mold half 1530, may form dimples in the outer layer of thermoplastic film 1515. In some embodiments, the protuberances 1525 may extend outward from the first curved inner surface 1522 in such a manner as to form dimples in the outer layer of thermoplastic film 1515 as well as in the golf ball core 1510. Similarly, the protuberances 1535 may extend outward from the second curved surface 1532 in such a manner as to form dimples in the outer layer of thermoplastic film 1515 as well as in the golf ball core 1510.

In some embodiments, the first mold half 1520 may include provisions for applying positive and/or negative pressure to the golf ball components during the molding process. Referring to FIG. 15, first mold half 1520 may include a first passage 1542 and a second passage 1546 capable of providing positive pressure and/or negative pressure (e.g., a vacuum) during the molding process. After the first mold half 1520 and second mold half 1530 are brought together, positive pressure and/or negative pressure may be provided at the outer end 1543 of first passage 1542 and at the outer end 1547 of second passage 1546. In some embodiments, the outer end 1543 of the first passage 1542 may be located on a first exterior surface 1528 of the first mold half 1520, while the inner end 1544 may be located on the first curved inner surface 1522. In some embodiments, the outer end 1547 of the second passage 1546 may be located on a second exterior surface 1529 of the first mold half 1520, while the inner end 1548 may be located on the first curved inner surface 1522. Providing positive pressure and/or negative pressure at the outer end 1543 of first passage 1542 and at the outer end 1547 of second passage 1546 may result in a positive pressure and/or negative pressure at the inner end 1544 of first passage 1542 and the inner end 1548 of second passage 1546.

In some embodiments, the second mold half 1530 may include provisions to apply positive and/or negative pressure to the golf ball components during the molding process. Referring to FIG. 15, second mold half 1530 may include a third passage 1552 and a fourth passage 1556 capable of providing positive pressure and/or vacuum pressure during the molding process. After the first mold half 1520 and second mold half 1530 are brought together, a positive pressure and/or negative pressure may be provided at the outer end 1553 of third passage 1552 and at the outer end 1557 of fourth passage 1556. In some embodiments, the outer end 1553 of the third passage 1552 may be located on a first exterior surface 1538 of the second mold half 1530, while the inner end 1554 may be located on the second curved inner surface 1532. In some embodiments, the outer end 1557 of the fourth passage 1556 may be located on a second exterior surface 1539 of the second mold half 1530, while the inner end 1558 may be located on the second curved inner surface 1532. Providing positive pressure and/or negative pressure at the outer end 1553 of third passage 1552 and at the outer end 1557 of fourth passage 1556 may result in a positive pressure and/or negative pressure at the inner end 1554 of third passage 1552 and the inner end 1558 of fourth passage 1556.

In some embodiments, each mold half may correspond to another mold half. Referring to FIG. 15, first mold half 1520 may correspond with second mold half 1530. In some embodiments, first mold half 1520 may include a first interior edge surface 1523 and a second interior edge surface 1524. In some embodiments, second mold half 1530 may include a first interior edge surface 1533 and a second interior edge surface 1534. In some embodiments, the first interior edge surface 1523 of the first mold half 1520 may be brought into contact with the first interior edge surface 1533 of the second mold half 1530. Simultaneously, the second interior edge surface 1524 of the first mold half 1520 may be brought into contact with the second interior edge surface 1534 of the second mold half 1530.

In some embodiments, compression forces may cause the thermoplastic film 1015 to bond with the golf ball core 1510 once the first mold half 1520 is brought into contact with the second mold half 1530. Referring to FIG. 16, the first interior edge surface 1523 of the first mold half 1520 may contact the first interior edge surface 1533 of the second mold half. Likewise, the second interior edge surface 1524 of the first mold half 1520 may be brought into contact with the second interior edge surface 1534 of the second mold half 1530. In some embodiments, the first curved inner surface 1522 and the second curved inner surface 1532 may exert forces on the golf ball components causing the thermoplastic film 1015 to bond to the golf ball core 1510. In some embodiments, protuberances 1525 on the first curved inner surface 1522, as well as protuberances 1535 on the second curved inner surface 1532, may form dimples in the thermoplastic film 1515. In some embodiments, dimples may also form in the golf ball core 1510.

In some embodiments, positive pressure may be applied through the passages in FIG. 16, causing the thermoplastic film 1515 to be forced against the golf ball core 1510. In some embodiments, positive pressure may be applied through the first passage 1542, second passage 1546, third passage 1552, and/or fourth passage 1556. For example, positive pressure may be provided at the outer end 1543 of first passage 1542 and at the outer end 1547 of second passage 1546, resulting in positive pressure at the inner end 1544 of first passage 1542 and the inner end 1548 of second passage 1546. Similarly, positive pressure may be provided at the outer end 1553 of third passage 1552 and at the outer end 1557 of fourth passage 1556, resulting in a positive pressure at the inner end 1554 of third passage 1552 and the inner end 1558 of fourth passage 1556. In some embodiments, a positive pressure applied through the passages may align the axis of some of the molecules in the thermoplastic film 1515.

In some embodiments, vacuum pressure may be applied through the passages in FIG. 16, causing the thermoplastic film 1515 to be forced against the first curved inner surface 1522 and/or second curved inner surface 1532. In some embodiments, vacuum pressure may be applied through the first passage 1542, second passage 1546, third passage 1552, and/or fourth passage 1556. For example, vacuum pressure may be provided at the outer end 1543 of first passage 1542 and at the outer end 1547 of second passage 1546, resulting in a vacuum at the inner end 1544 of first passage 1542 and the inner end 1548 of second passage 1546. Similarly, vacuum pressure may be provided at the outer end 1553 of third passage 1552 and at the outer end 1557 of fourth passage 1556, resulting in a vacuum at the inner end 1554 of third passage 1552 and the inner end 1558 of fourth passage 1556. In some embodiments, vacuum pressure applied through the passages may align the axis of some of the molecules in the thermoplastic film 1515.

In some embodiments, positive pressure may be applied through some of the passages and vacuum pressure may be applied through other passages. In some embodiments, vacuum pressure may be provided at the outer end 1543 of first passage 1542 and a positive pressure may be applied at the outer end 1547 of second passage 1546. This may result in a vacuum at the inner end 1544 of first passage 1542 and positive pressure at the inner end 1548 of second passage 1546. Similarly, vacuum pressure may be provided at the outer end 1553 of third passage 1552 and positive pressure may be applied at the outer end 1557 of fourth passage 1556. This may result in a vacuum at the inner end 1554 of third passage 1552 and positive pressure at the inner end 1558 of fourth passage 1556. In some embodiments, applying positive pressure in some of the passages and vacuum pressure in other passages may align the axis of some of the molecules in the thermoplastic film 1515.

In some embodiments, heat may be applied to the mold halves. Applying heat to the mold halves may facilitate the thermoplastic film 1515 bonding onto the golf ball core 1510. Additionally, heat may also facilitate the alignment of some of the molecules in the thermoplastic film. In some embodiments, the entire mold may be subjected to a heat source. In other embodiments, heated air may be supplied through the outer end 1543 of the first passage 1542, the outer end 1547 of the second passage 1546, the outer end 1553 of the third passage 1552, and/or the outer end 1557 of the fourth passage 1556. In still further embodiments, a heating element (not shown) may be included near the first curved inner surface 1522 and/or the second curved inner surface 1532.

Once the first mold half 1520 and second mold half 1530 separate, a robotic arm 1505 may grip the outer thermoplastic layer 1515 of the golf ball. Referring to FIG. 17, the forces exerted on the golf ball components may cause the thermoplastic film 1515 to form an outer layer on the golf ball core 1510. In some embodiments, dimples 1560 may be formed on the outer surface of the golf ball caused by the protuberances 1525 in the first mold half 1520 and protuberances 1535 in the second mold half 1530. However, in other embodiments the first curved inner surface 1522 and second curved inner surface 1532 may be smooth. In such an embodiment, the outer surface of the thermoplastic layer 1515 may be smooth and may not have the dimples 1560 illustrated in FIG. 17.

Although each mold half has two passages in FIGS. 15-17, other embodiments may include more or less passages. In some embodiments, each mold half may have less than two passages. In other embodiments, each mold half may have more than two passages.

In some embodiments, a plurality of molds may be used to manufacture golf balls. In some embodiments, molds may be mounted on conveyer belts in order to reduce manufacturing time and increase efficiency. FIG. 18 is a schematic view of methods and systems 1800 for manufacturing a golf ball using a plurality of conveyer belts. Referring to FIG. 18, a first conveyer belt 1815 may rotate in a first direction 1802, while a second conveyer belt 1865 may rotate in a second direction 1804. In some embodiments, first conveyer belt 1815 may be in contact with the circumference of a first wheel 1840 and the circumference of a second wheel 1842. In some embodiments, a power source (not shown) may be electrically connected to the first wheel 1840 and second wheel 1842 causing the first wheel 1840 and second wheel 1842 to rotate. The rotation of the first wheel 1840 and second wheel 1842 may cause the first conveyer belt 1815 to move in the first direction 1802. Likewise, second conveyer belt 1865 may be in contact with the circumference of a third wheel 1890 and the circumference of a fourth wheel 1892. In some embodiments, a power source (not shown) may be electrically connected to the third wheel 1890 and fourth wheel 1892 causing the third wheel 1890 and fourth wheel 1892 to rotate. The rotation of the third wheel 1890 and fourth wheel 1892 may cause the second conveyer belt 1865 to move in the second direction 1804.

In some embodiments, the type of power source may vary. In some embodiments, the power source may be an electric motor. In other embodiments, the power source may be an internal combustion engine. In still further embodiments, other power sources known to those skilled in the art may also be provided.

In some embodiments, the first conveyer belt 1815 and second conveyer belt 1865 may include a plurality of mold halves. Referring to FIG. 18, first conveyer belt 1815 may include a first mold half 1820, second mold half 1822, third mold half 1824, and fourth mold half 1826. Likewise, second conveyer belt 1865 may include a fifth mold half 1870, sixth mold half 1872, seventh mold half 1874, and eighth mold half 1876. In other embodiments, more or less mold halves shown in FIG. 18 may be provided.

In some embodiments, each mold half may be similar to. In some embodiments, first mold half 1820, second mold half 1822, third mold half 1824 and fourth mold half 1826 may be similar to the first mold half 1520 shown in FIGS. 15-17. In some embodiments, fifth mold half 1870, sixth mold half 1872, seventh mold half 1874 and eighth mold half 1876 may be similar to the second mold half 1530 shown in FIGS. 15-17. In other embodiments, first mold half 1820, second mold half 1822, third mold half 1824, fourth mold half 1826, fifth mold half 1870, sixth mold half 1872, seventh mold half 1874 and eighth mold half 1876 may have more or less features than the first mold half 1520 and second mold half 1530 shown in FIGS. 15-17.

In some embodiments, a robotic arm (not shown) may position the golf ball components 1806 between first mold half 1820 and fifth mold half 1870. In some embodiments, the robotic arm discussed in FIGS. 1-3 may be used in conjunction with the embodiment 1800 shown in FIG. 18. In some embodiments, golf ball components 1806 may be formed by the methods and systems described in FIGS. 4-17.

In some embodiments, each mold half shown in FIG. 18 may be associated with an extension arm. For example, second mold half 1822 is associated with extension arm 1830, and third mold half 1824 is associated with extension arm 1832. Similarly, sixth mold half 1872 is associated with extension arm 1880, and seventh mold half 1874 is associated with extension arm 1882. In some embodiments, first mold half 1820, fourth mold half 1826, fifth mold half 1870 and eighth mold half 1876 may also be associated with extension arms. In FIGS. 15-17, an extension arm may be associated with the third exterior surface 1527 of the first mold half 1520, as well as the third exterior surface 1537 of the second mold half 1530.

In some embodiments, each extension arm may be capable of extending outwardly from the conveyer belt causing each mold half to come into contact with a mold half from the opposing conveyer belt. For example, FIG. 18 shows extension arm 1830 extending second mold half 1822 outwardly from first conveyer belt 1815, and extension arm 1880 extending sixth mold half 1872 outwardly from second conveyer belt 1865, so that second mold half 1822 and sixth mold half 1872 contact one another. In some embodiments, each mold half may contact its corresponding mold half as described and illustrated in FIG. 16. In some embodiments, each extension arm may be capable of retracting inwardly back towards the conveyer belt, resulting in each mold half returning to the surface of the conveyer belt.

In some embodiments, a robotic arm (not shown) may remove the golf ball 1808 when the mold halves separate. For example, a robotic arm may grip golf ball 1808 once the fourth mold half 1826 separates from the eighth mold half 1876. In some embodiments, the robotic arm discussed in FIGS. 1-3 may be used in conjunction with the embodiment 1800 shown in FIG. 18. In some embodiments, the outer surface of the golf ball 1808 may have dimples. In other embodiments, the golf ball 1808 may have a smooth outer surface.

Some embodiments may include golf ball assembling methods and systems 1900 having mold halves that are different from one another. In such an embodiment, each mold half may perform a specific function. FIG. 19 is a schematic view of one embodiment of a golf ball manufacturing assembly 1900 wherein each mold half performs a specific function.

As can be seen in FIG. 19, connected golf ball components 1902 may be positioned between a first mold half 1910 and a second mold half 1920. In some embodiments, the robotic arm discussed in FIGS. 1-3 may position the connected golf ball components 1902 between the first mold half 1910 and the second mold half 1920. In some embodiments, connected golf ball components 1902 may be formed by the methods and systems described in FIGS. 4-17.

In some embodiments, first mold half 1910 may be associated with a first extension arm 1911, and second mold half 1920 may be associated with a second extension arm 1921. In some embodiments, first extension arm 1911 may urge first mold half 1910 towards the second mold half 1920, and second extension arm 1921 may urge second mold half 1920 towards the first mold half 1910. In some embodiments, first mold half 1910 and second mold half 1920 may come into contact with one another so as to separate the connected golf ball components 1902. In some embodiments, the first extension arm 1911 may pull the first mold half 1910 away from the second mold half 1920, and the second extension arm 1921 may pull the second mold half 1920 away from the first mold half 1910. In some embodiments, the robotic arm discussed in FIGS. 1-3 may be used to retrieve the isolated golf ball components 1903 from the first mold half 1910 and the second mold half 1920.

In some embodiments, the robotic arm discussed in FIGS. 1-3 may then position the isolated golf ball components 1903 between the third mold half 1912 and fourth mold half 1922. In some embodiments, third mold half 1912 may be associated with a third extension arm 1913, and fourth mold half 1922 may be associated with a fourth extension arm 1923. In some embodiments, third extension arm 1913 may urge third mold half 1912 towards the fourth mold half 1922, and fourth extension arm 1923 may urge the fourth mold half 1922 towards the third mold half 1912. In some embodiments, third mold half 1912 and fourth mold half 1922 may come into contact with one another so as to exert compressive forces on the isolated golf ball components 1902. In some embodiments, the third extension arm 1913 may pull the third mold half 1912 away from the fourth mold half 1922, and the fourth extension arm 1923 may pull the fourth mold half 1922 away from the third mold half 1912. The compressive forces exerted by the third mold half 1912 and fourth mold half 1922 may cause the thermoplastic film to bond to the golf ball core, forming a golf ball 1905 having smooth surface. Additionally, third mold half 1912 and fourth mold half 1922 may come into contact with one another so as to trim away excess thermoplastic film. In some embodiments, the thermoplastic seam material that was cut or removed may be recycled and may be used to form another roll of thermoplastic film. In some embodiments, the robotic arm discussed in FIGS. 1-3 may be used to retrieve the golf ball 1905 having a smooth surface from between the third mold half 1912 and fourth mold half 1922.

In some embodiments, the robotic arm discussed in FIGS. 1-3 may then position the golf ball 1905 having a smooth surface between the fifth mold half 1914 and sixth mold half 1924. In some embodiments, the fifth mold half 1914 may be associated with a fifth extension arm 1915, and the sixth mold half 1924 may be associated with a sixth extension arm 1925. In some embodiments, the fifth extension arm 1915 may urge the fifth mold half 1914 towards the sixth mold half 1924, and the sixth extension arm 1925 may urge the sixth mold half 1924 towards the fifth mold half 1914. In some embodiments, the fifth mold half 1914 and sixth mold half 1924 may come into contact with one another so as to form dimples in the outer surface of the smooth golf ball 1905. In some embodiments, the fifth extension arm 1915 may pull the fifth mold half 1914 away from the sixth mold half 1924, and the sixth extension arm 1924 may pull the sixth mold half 1924 away from the fifth mold half 1914. In some embodiments, the robotic arm discussed in FIGS. 1-3 may be used to retrieve the dimpled golf ball 1907 from between the fifth mold half 1914 and sixth mold half 1924.

The outer surface of the golf ball resulting from the processes described in FIGS. 4-19 may vary. In some embodiments, the golf ball may have a hardness of 40-70 Shore D. In other embodiments, the golf ball may have a hardness that is less than 40 Shore D. In still further embodiments, the golf ball may have a hardness that is greater than 70 shore D. In some embodiments, the outer surface of the golf ball may have dimples. However, in other embodiments, the outer surface of the golf ball may be smooth.

While some of the current embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the current disclosure. Accordingly, the current embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Further, in describing the embodiments, the specification may have presented methods and/or processes as a particular sequence of steps. However, to the extent that the methods or processes do not rely on the particular order of steps set forth herein, the methods or processes should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to methods and/or processes should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied. Additionally, any element of any embodiment described herein may be utilized in any other embodiment as an additional element or a substitution of an element unless specifically limited herein. 

We claim:
 1. A method of preparing thermoplastic film, comprising: providing a sheet of thermoplastic film; providing a heat source; applying the heat source to the thermoplastic film; stretching the thermoplastic film in a first direction; and stretching the thermoplastic film in a second direction, wherein the second direction is substantially perpendicular to the first direction.
 2. The method of claim 1, wherein the steps of stretching the thermoplastic film in a first direction and stretching the thermoplastic film in a second direction is performed using a robotic arm.
 3. The method of claim 1, further comprising: providing a golf ball core having an outer surface; providing a robotic arm; gripping the golf ball core with the robotic arm; and disposing the thermoplastic film on the outer surface of the golf ball core while gripping the golf ball core with the robotic arm.
 4. The method of claim 3, wherein disposing the thermoplastic film on the outer surface of the golf ball core further comprising: forming a crease in the thermoplastic film so that the thermoplastic film is substantially L-shaped.
 5. The method of claim 4, wherein disposing the thermoplastic film in the outer surface of the golf ball core further comprising: positioning the golf ball core in the crease of the thermoplastic film while gripping the golf ball core with the robotic arm.
 6. The method of claim 5, wherein disposing the thermoplastic film on the outer surface of the golf ball core further comprising: folding the thermoplastic film into a U-shape around the outer surface of the golf ball core while the robotic arm is gripping the golf ball core.
 7. The method of claim 3, further comprising: placing the golf ball core into a mold using the robotic arm after the thermoplastic film is disposed around the outer surface of the golf ball core.
 8. A method for manufacturing a golf ball, comprising: disposing a biaxial thermoplastic film on an outer surface of a golf ball core; providing a robotic arm; gripping the golf ball core having the biaxial thermoplastic film disposed around the outer surface of the golf ball core with the robotic arm; providing a first mold half having a first inner surface and a first outer surface; providing a second mold half having a second inner surface and a second outer surface, wherein the second inner surface is facing the first inner surface; and positioning the golf ball core having the biaxial film disposed on the outer surface of the golf ball core between the first inner surface and second inner surface using the robotic arm.
 9. The method in claim 8, wherein the first inner surface of the first mold half includes a first plurality of protuberances, and the second inner surface of the second mold half includes a second plurality of protuberances.
 10. The method of claim 8, wherein the first mold half includes a first passage extending throughout the first mold half, wherein the first passage having a first opening at the first inner surface of the first mold half and a second opening at the outer surface of the first mold half.
 11. The method of claim 10, wherein a positive pressure source is connected to the second opening of the first passage of the first mold half.
 12. The method of claim 10, wherein a vacuum source is connected to the second opening of the first passage of the first mold half.
 13. The method of claim 8, wherein the first outer surface of the first mold half is associated with a first extension arm and the second outer surface of the second mold half is associated with a second extension arm.
 14. The method of claim 13, wherein the first extension arm is associated with a first conveyer belt and the second extension arm is associated with a second conveyer belt.
 15. A method for manufacturing a golf ball, the method comprising: providing a golf ball core; gripping a golf ball core with a first robotic arm; providing a first sheet of thermoplastic film having a first surface and a second surface; providing a second sheet of thermoplastic film having a first surface and a second surface, wherein the first surface of the second sheet is facing the first surface of the first sheet; and positioning the golf ball core between the first surface of the second sheet of thermoplastic film and the first surface of the first sheet of thermoplastic film with the robotic arm.
 16. The system in claim 15, further comprising: providing a first mold half having a first inner surface; providing a second mold half having a second inner surface; placing the first inner surface in contact with the second surface of the first sheet; and placing the second inner surface in contact with the second surface of the second sheet.
 17. The system in claim 15, wherein the first sheet of thermoplastic and the second sheet of thermoplastic are substantially biaxial.
 18. The system in claim 16, wherein the first sheet of thermoplastic film becomes substantially biaxial after the second surface of the first sheet contacts the first inner surface of the first mold half.
 19. The system in claim 15, further comprising: applying a heat source to the first and second sheet of thermoplastic film.
 20. The system in claim 16, wherein a second robotic arm places the first inner surface in contact with the second surface of the first sheet, and wherein a third robotic arm places the second inner surface in contact with the second surface of the second sheet. 